ATTIC STEP

Abstract

A step for installation into an attic that is easily installed on the existing beams within a typical attic to provide a safer and easier means to maneuver within a home's attic space. The step is produced using a single piece of sheet metal. In addition, the step is installed into the attic by securing teeth on the bendable tabs of the step to the existing beams using a hammer with the optional use of additional fasteners.

Description

BACKGROUND OF THE INVENTION

The present invention relates to an attic step, and in particular to an attic step that can be fastened to the existing truss beams typically found in attics.

People need to maneuver around within a home's attic space during home construction and for maintenance and inspection requirements in existing homes. Because ceilings are attached to the underside of trusses, people have to be careful where they step in attics so as to avoid falling through or damaging the ceiling. This task can be particularly difficult when insulation covers part of or all of the ceiling, thereby making it more difficult for the person to determine where to step while moving around in the attic. The difficulty with this task can be enhanced when a portion of the trusses are also covered by insulation thereby making it unclear whether there is a board to step onto while moving around within the attic.

Some people step into the V-shape where beams of the trusses meet, as a means for maneuvering in the attic. However, this approach is both inconvenient and dangerous as the person's foot is wedged at an angle and into a potential pinch point between the wooden beams of the trusses. Alternatively, permanent lumber can be installed on the horizontal portion of the trusses. However, installation of permanent lumber is time-consuming and expensive and also compresses the limits to the amount of insulation that can be used in the attic. The installation of permanent lumber can also add weight above the ceiling, thereby increasing the chances of the plaster or drywall cracking. It can also potentially restrict the expansion and contraction of the truss structure which can cause cracks in the plaster or drywall of the ceiling. Yet another way has been to use loose boards in the attic space and move them across the attic while a person attempts to traverse across the space. This too can be cumbersome and time-consuming and also compresses the insulation.

While there are known ways for people to traverse around within an attic, improvements to products and methods for moving around the attic would be clearly advantageous, and are disclosed herein.

SUMMARY OF THE INVENTION

According to one aspect of the present invention, an attic step includes a base with a plurality of flanges extending from at least one side of the base. The flanges are spaced apart to closely receive a truss beam. The attic step also includes a plurality of tabs extending from the base, with a plurality of teeth extending from the tabs.

According to another aspect of the present invention, a method for installing attic steps in an attic includes forming an attic step from a single piece of metal. The step includes a base with two flanges extending from the left and right sides of the base. The flanges on each side are spaced apart to create a gap between the flanges. The step also has a tab extending from the left and right sides of the base. The step is placed over a truss such that at least one beam of the truss is closely received in the gap between the flanges on the left and/or right sides of the base. One or both tabs are bent to closely engage the truss beam(s).

According to yet another aspect of the invention, a method of manufacturing an attic step includes selecting a piece of metal stock and stamping the piece to form a one-piece attic step. The attic step has a base, two flanges extending from the left and right sides of the base, a tab extending from the left and right sides of the base, and a plurality of teeth extend from each tab.

The attic step can include any combination of one or more of the following features:

• • Stamped sheet metal
  • An embossed surface that provides strength to the sheet metal while also providing an anti-slip surface
  • Flanges to provide rotational support of the step
  • Bendable tabs with built-in teeth for securing the step to wood trusses
  • Fastener holes through which fasteners can be inserted into the attic step to secure it to truss beam(s)
  • Alternative mounting configurations
  • Installation accomplished by using a hammer
  • A design that allows the attic steps to be stackable for ease of storage, transportation, or display of multiple attic steps.
  • A rubberized surface added to all of or a portion of the attic step to enhance the traction and/or durability of the attic step.

These and other advantages of the invention will be further understood and appreciated by those skilled in the art by referencing the following written specification, claims, and appended drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a fragmentary perspective view of an attic step embodying the present invention, installed on truss beams.

FIG. 2 is a perspective view of the attic step shown in FIG. 1.

FIG. 3 is a fragmentary perspective view of a plurality of attic steps installed in an attic.

FIG. 4 is a perspective view of a plurality of stacked attic steps.

FIG. 5 is a fragmentary perspective view of the attic step with the flange shown in alternative positions, one of which is shown in phantom.

FIG. 6 is a fragmentary top view of another embodiment of the base surface of the attic step.

FIG. 7 is a fragmentary top view of another embodiment of the base surface of the attic step.

FIG. 8 is a fragmentary top view of another embodiment of the base surface of the attic step.

FIG. 9 is a fragmentary top view of another embodiment of the base surface of the attic step.

FIG. 10A is a fragmentary perspective view of the attic step before installation on truss beams.

FIG. 10B is a fragmentary perspective view of the attic step in place on truss beams.

FIG. 10C is a fragmentary perspective view of the attic step in place on a truss beam with an arrow showing the direction of force to be placed on the tab.

FIG. 10D is a fragmentary perspective view of the attic step with fasteners placed into the fastener apertures in the tabs.

FIG. 11 is a top view of another embodiment of an attic step embodying the present invention.

FIG. 12 is a perspective view of the attic step shown in FIG. 11.

FIG. 13 is a front view of the attic step shown in FIG. 11.

FIG. 14 is a side view of the attic step shown in FIG. 11.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof, shall relate to the invention as oriented in the attached drawings. However, it is to be understood that the invention may assume various alternative orientations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification, are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting unless the claims expressly state otherwise.

The inventive attic step 2, shown in FIG. 1, can provide a safe and stable surface to walk on in an attic 20 that has truss beams 14, as shown in FIG. 3. While the truss beams 14 are typically wood, the inventive attic step 2 can be used on beams made of other materials, including metal. In addition, the beams can have a rounded or milled edge 15. The attic step 2 includes a base 4, that operates as a step area, flanges 12, and tabs 6. As illustrated in FIGS. 1, 2, and 4, the flanges 12 extend generally downwardly and slightly outwardly from the base 4 and the tabs 6 extend upwardly and slightly outwardly from the base 4.

As shown in FIG. 2, the flanges 12 have an outside surface 27 and an inside surface 28. A gap 29 is formed between the inside surfaces 28 of corresponding flanges 12 on the right and left sides of the attic step 2. The gap 29 is spaced to closely receive a beam 14 of an attic truss. Given that an attic beam has a width of approximately 1½ inches, the gap 29 will be approximately 1½ inches. The flanges 12 have an end 15 that is proximate the base and an end 13 that is distal from the base. While the gap 29 is illustrated as having a uniform width from the distal ends 13 to proximal ends 15 of the flanges 12, the gap 29 may be tapered such that the width of the gap 29 that is nearest the proximal ends 15 of the flanges 12 is narrower than the width of the gap at the distal ends 13 of flanges 12. Accordingly, the gap 29 can have a width of less than 1½ inches in between the proximal ends 15 of the corresponding flanges 12. Because the truss beam(s) are closely received in the left and/or right gaps 29, the corresponding flanges 12 provide rotational support of the attic step 2.

The tabs 6 are bendable at the end 9 of tab 6 that is proximate the base 4. The distal ends 7 of the tabs 6 has a plurality of teeth 8. The tabs 6 also have fastener apertures 10. The tabs 6 can be bent so that the teeth 8 are inserted into a truss beam 14. This can be accomplished by applying pressure to the tab 6 using a hammer or similar device. As illustrated in FIG. 5, tab 6 can be bent to engage a relatively flat beam 14. When the tab 6A (shown in phantom) is bent, the corresponding teeth 8A and fastener apertures 10A will also go into a similar orientation.

While the illustrated attic 20 (FIG. 3) includes insulation 18 and V-shaped trusses with beams 14, it is to be understood that this attic step 2 may be used in attics 20 that do not include insulation 18 or that include trusses with beams 14 that are shaped such that the beams 14 do not come to a V-shape. As illustrated in FIG. 1, trusses do typically include multiple beams 14 that are connected by a plate 22. As illustrated in FIG. 3, when the attic step 2 is installed in an attic 20, the attic step can be placed such that the step area 4 is above the insulation 18 to create a path to allow a person to walk from truss to truss.

As illustrated in FIG. 2, the base 4 includes a plurality of protrusions 16 to create a textured surface to increase the gripability of the base 4 for a person to step on. Such textured surfaces help prevent slipping by increasing the friction between a person's foot and the base 4 as compared to an entirely flat, non-textured surface. As illustrated in FIGS. 6-9, the textured surface of the base 4 can be altered to include any combination of surface texture to increase the gripability of the base 4 when a person steps on the attic step 2. For example, in FIG. 6, the base 4 includes generally circular holes 34 that include a raised area 32. With respect to FIG. 7, the base 4 can have a plurality of tread-like protrusions 36. FIG. 8 illustrates another textured surface for base 4 that includes raised areas 42 between holes 38 and 40. Holes 38, 40 are elongated, with the holes 38 having raised protrusions. FIG. 9 illustrates yet another exemplary embodiment of the base 4 with a plurality of holes 44 with corresponding rows of holes 44 offset to create a textured surface. Moreover, any combination of these embodiments or other textured surfaces (including, but not limited to, protrusions, indentations, and holes) can be used. In addition, a surface treatment can be added to the base 4. For example, base 4 could have a rubberized surface, a sandpaper-like surface, or other surface applied to the one-piece metal attic step 2. Such surfaces can be coated, sprayed, or adhered to the base 4 of the attic step 2. In addition, such surface could also be added to other portions of the attic step 2.

The attic step 2 is installed on a truss 14 by lowering the attic step 2 onto the truss beams 14, as illustrated by the arrow in FIG. 10A. When the attic step 2 is placed onto the beam 14, the beam 14 is closely received in the gap 29 between the flanges 12. As illustrated in FIG. 10B, the attic step 2 is placed in a generally horizontal orientation on beams 14 so that it is generally level. Once the attic step 2 is level, the tab 6 is advanced toward beam 14, such that the teeth 8 are inserted into the beam 14, as shown by the arrow in FIG. 10C. Fasteners 26 can be inserted into fastener apertures 10 to further secure the tabs 6 and the attic step 2 to the beams 14 of the truss, as shown in FIG. 10D. The fasteners 26 can be any conventional fastener, including, but not limited to, nails or screws. In addition, an adhesive (not shown) can be used to help secure the attic step 2 to the beams 14, particularly when the beams 14 are metal.

An additional embodiment of an attic step 52 is shown in FIGS. 11-14. The attic step 52 includes a base 54 that has protrusions 62 and holes 64. The protrusions 62 can include a serrated or raised edge. The attic step 52 also includes tabs 56 and flanges 53 that extend from the base 54. The tabs 56 have a pair of integrally formed teeth 58 at the distal ends 50 of the tabs 56 and a fastener aperture 60. The end 51 of the tab 56 that is proximate the base 54 can include a hole 70. The hole 70 can facilitate the bending of the tab 56 by creating less surface area at the end 51 where the tab 56 extends from the base 42.

The flanges 53 include outward edges 55 and inward edges 57 with a gap 59 between the inward edges of corresponding flanges 53. The flanges 53 are spaced apart such that the gap 59 can closely receive an attic beam 14 as described above.

The attic steps 2 and 52 are manufactured from a single piece of metal stock. The metal stock is stamped and/or cut to form a one-piece attic step 2, 52 that has an integral base 4, 54 with integral flanges 12, 53 and integral tabs 6, 56 with teeth 8, 58. For example, the attic step 2 can be made in a progressive metal forming die. As described above, surface texturing or treatments may be applied to the attic step 2.

As illustrated in FIG. 4, the attic step is shaped so that multiple attic steps can be stacked one upon the other to make storage, shipment, and installation of the attic steps easier to accomplish.

It will be understood by one having ordinary skill in the art that construction of the described invention and other components is not limited to any specific material. Other exemplary embodiments of the invention disclosed herein may be formed from a wide variety of materials, unless described otherwise herein.

It is also important to note that the construction and arrangement of the elements of the invention as shown in the exemplary embodiments is illustrative only. Although only a few embodiments of the present innovations have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, the operation of the interfaces may be reversed or otherwise varied, the length or width of the structures and/or members or connector or other elements of the system may be varied, the nature or number of adjustment positions provided between the elements may be varied. It should be noted that the elements and/or assemblies of the system may be constructed from any of a wide variety of materials that provide sufficient strength or durability, in any of a wide variety of textures and combinations. Accordingly, all such modifications are intended to be included within the scope of the present innovations. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangement of the desired and other exemplary embodiments without departing from the spirit of the present innovations.

It will be understood that any described processes or steps within described processes may be combined with other disclosed processes or steps to form structures within the scope of the present invention. The exemplary structures and processes disclosed herein are for illustrative purposes and are not to be construed as limiting.

It is also to be understood that variations and modifications can be made on the aforementioned structure without departing from the concepts of the present invention, and further it is to be understood that such concepts are intended to be covered by the following claims unless these claims by their language expressly state otherwise.

Claims

1. A step for an attic, comprising: a base;a plurality of flanges extending from at least one side of said base, wherein the flanges are spaced apart to approximately 1½ inches;a plurality of tabs extending from said base; anda plurality of teeth extending from said tabs.

2. A step for an attic as set forth in claim 1, including a plurality of flanges extending from the side of the base that is opposite said at least one side of the base, wherein the flanges are spaced apart to approximately 1½ inches.

3. A step for an attic as set forth in claim 2, wherein said plurality of flanges on opposing sides of the base comprises two flanges on each side.

4. A step for an attic as set forth in claim 1, wherein the plurality of tabs includes a single tab extending from said at least one side of the base and a single tab extending from the opposite side of the base.

5. A step for an attic as set forth in claim 4, wherein the tab extends upwardly and outwardly from the base.

6. A step for an attic as set forth in claim 1, wherein the tabs are bendable at the point where the tabs connect to the base.

7. A step for an attic as set forth in claim 1, wherein two or more teeth extend outwardly from the distal end of the tab.

8. A step for an attic as set forth in claim 1, wherein said base, said plurality of flanges, said plurality of tabs, and said plurality of teeth are integrally formed from a single piece of metal.

9. A step for an attic as set forth in claim 1, wherein the base includes a textured surface.

10. A step for an attic as set forth in claim 9, wherein the textured surface comprises a plurality of protrusions.

11. A step for an attic as set forth in claim 8, wherein a rubberized surface is added to the base.

12. A method for installing steps in an attic comprising: forming a step from a single piece of metal, said step including a base, two flanges extending from the left and right sides of the base spaced apart to create a gap between the flange, and a tab extending from the left and right sides of the base;placing the step over a truss such that at least one beam of the truss is closely received in said gap between said flanges on either the left or right sides of the base; andbending a tab to closely engage said at least one beam.

13. The method for installing steps in an attic as set forth in claim 12, wherein the forming step includes forming a plurality of teeth extending from each tab.

14. The method for installing steps in an attic as set forth in claim 12, wherein the bending step includes inserting the plurality of teeth of said tab into said at least one beam.

15. The method for installing steps in an attic as set forth in claim 12, wherein the forming step includes forming one or more fastener apertures in one or more of the tabs.

16. The method for installing steps in an attic as set forth in claim 15, including securing the tabs to the at least one beam by installation of a fastener into one or more fastener apertures to secure the tab to said at least one beam.

17. The method for installing steps in an attic as set forth in claim 12, including installing multiple steps in an attic to create a path to walk from truss to truss in the attic.

18. The method for installing steps in an attic as set forth in claim 12, wherein the placing step includes placing the step over a truss such that a truss beam is closely received in the tabs between said flanges on both the right and left sides of the base.

19. A method of manufacturing an attic step comprising: selecting a piece of metal stock;forming said piece of metal stock into an attic step having a base, two flanges extending from the left and right sides of the base, a tab extending from the left and right sides of the base, and a plurality of teeth extend from each tab.

20. A method of manufacturing an attic step as set forth in claim 19, wherein the base is formed with a textured surface.